Method of finishing a drywall and a compound therefor

ABSTRACT

The method for sealing a seam between adjacent structural panels significantly reduces the time for finishing a drywall in comparison with conventional methods, which use multiple applications of a joint compound to seal the seam. An all-purpose drywall joint compound is mixed with a synthetic fiber, such as Colombian Fiber, or polypropylene, and sufficient water to facilitate soaking of the synthetic fiber and mixing with the joint compound. An optional liquid adhesive, such as liquid wallpaper adhesive, is added to the mixture. The mixture is then applied as one coat to the seam and allowed to dry. No subsequent coatings of the mixture are necessary.

BACKGROUND OF THE INVENTION

[0001] This invention relates to drywall finishing, and more particularly to a method of reducing the time required to finish drywall joints and to drywall joints compound therefor.

[0002] The building industry widely uses gypsum board in the construction of residential homes, commercial buildings, and other structures. The gypsum board, also known as sheetrock or drywall is usually pre-cut in flat sheets of 4×12 foot, having a thickness of ½ or ⅛ of an inch. The sheets of the gypsum board are hung on wood or still studs to form an interior wall of the building. Typical walls have joints between the sheetrock segments that must be covered to form a smooth surface for application of the wallpaper or paint.

[0003] A conventional method of finishing the drywall comprises a number of steps. First, a drywall joint compound is deposited along the joint as a thin bead. The drywall joint compound usually has limestone, water, mica, vinyl acetate polymer and may also have talc. The limestone may be substituted by dolomite or gypsum. If the compound comes as a dry powder, it is mixed with the necessary amount of water, stirred and then applied with a six-inch joint finishing knife to the joint. Immediately after that, a drywall tape is placed over the bead of the drywall joint compound and the joint finishing knife is run over the tape to press the tape and cause it to adhere to the compound. Next the first coat of the compound is allowed to dry for 24 hours. Then a second coat of the joint compound is applied over the first coat to cover the tape completely and to cover the interface between the tape and the wall. Then the second coat is allowed to dry for 24 hours. The a third coat is applied with a 10-inch joint finishing knife to make a wide strip of joint compound on the wall that would entirely cover the tape as well as the first two coats. When the final coat dries, again for about 24 hours, it is sanded to remove imperfections and achieve a smooth finish. The dust is wiped off or blown off to make the wall ready for wallpaper or paint application.

[0004] The disadvantage of the conventional method is that it requires 3-4 days to finish one wall, with a 24 hour drying period between joint compound applications. The drywall finisher has to come back to the same job several times before the walls are finished. The time spent on finishing the walls is directly proportional to the cost of the building construction. It would be therefore a considerable advantage to provide a method that would reduce the labor time in finishing the drywall and thereby reduce the overall drywall finishing time.

[0005] The present invention contemplates provision of such a method and a novel compound for finishing a drywall that would reduce the curing time and eliminate the need for multiple joint compound applications.

SUMMARY OF THE INVENTION

[0006] It is, therefore, an object of the present invention to provide a method of finishing a drywall by eliminating the number of coats necessary to finish a drywall.

[0007] It is another object of the present invention to provide a drywall joint compound that has reduced curing time and is strong enough even with one application.

[0008] These and other objects of the present invention are achieved through the provision of a method. . .

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Reference will now be made to the drawing illustrating the method steps of the present invention, wherein FIG. 1 is a flow chart of the preferred embodiment of the method of finishing a drywall according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0010] The method of the present invention begins with preparing a compound for filling the drywall joints. The user makes an all purpose sheetrock compound fine chopped fiberglass and water and allows the fibers to soak for 1-3 minutes. The mixture is then vigorously agitated for 2-5 minutes and liquid vinyl wallpaper adhesive is added.

[0011] A thoroughly mixed mixture is then applied to the drywall joints, taking care to fill the entire joints, while taking care that the deposited coat of the mixture is in an even bead, extending on both sides of the joints and smoothed over with the joint finishing knife. The mixture is then allowed to dry for about 24 hours, after which time the wall is ready for application of the paint or wallpaper.

[0012] In the preferred embodiments, the sheetrock compound is selected from a group of conventional all-purpose joint compounds. Such compounds are manufactured by a number of companies in the United States, such as Gypsum Company of Chicago, Ill., National Gypsum Company of Shamrock, N.C., and others. The manufacturer may use limestones, dolomite or gypsum as the main ingredient, plaster of Paris, perlite, vinyl acetate polymer, mica (silicates of chemical composition), hydrated silicates (attapulgite clay), starch, crystallized silicone dioxide (quartz), water and latex. The synthetic fiber used in the preferred embodiment of the present application is the so called Columbian Fiber. This ingredient is available on the market, it is white, and has a specific gravity of 0.91. The synthetic fiber is polypropylene fiber, which is chopped up to ½ inch to 1 inch in length pieces and broken up to a fiber having a full diameter equal to approximately the diameter of human hair. The Columbian fiber soaks up the water in the joint compound while the limestone, gypsum, clay and other ingredients in the standard joint compound adhere to the fibers. The liquid vinyl wallpaper adhesive used in the composition of the present invention is readily available on the market from, for instance, Roman Adhesive, Inc. of Illinois. The adhesive is a vegetable base. It is translucent and has a specific gravity of 1.1. It is miscible in water in all proportions.

[0013] The composition of the present invention contains 97.68%-98.8% of all-purpose sheetrock compound, 0.247%-0.97% of water, 0.494%-0.73% of synthetic fiber, and 0.37%-0.61% by weight of the vinyl adhesive. The adhesive is selected from the family of vegetable adhesive.

[0014] The method of the present invention using the novel compound allows to significantly reduce the finishing time for drywalls. Usually, one coat of the compound is sufficient to cover the joint in a smooth bead of coating along the joint line and on both sides thereof. The second and third coat is not usually necessary. If desired, a finishing coating may be applied to the dried compound of the present invention to cover any possible imperfections created when applying the coat with the joint knife.

[0015] The present invention provides a method of reducing the labor time when finishing a drywall, eliminates multiple coatings of the joint with a joint compound, as well as dry sanding of the final coat of the joint compound. The present invention thus allows to significantly reduce the time for finishing the drywall and avoid any possible hazards from the dust created when the walls are sanded.

[0016] The joint compound of the present invention may be successfully used for repairing cracks or holes in the sheetrock wall without the need for mechanical devices that are conventionally used for covering the cracks or holes before the joint compound can be applied.

[0017] Due to the presence of synthetic fiber in the compound, the finished wall will not crack along the interface of the gypsum board sheets. The synthetic fiber allows for elative “flexibility” of the seam created withjoint compound which avoids any destruction in the smooth surface of the wall.

[0018] It is envisioned that the compound of the present invention may be also used for repairing seams and other areas of a building where a smooth, crack-free surface is desired.

[0019] Many changes and modifications in the method and compound of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims. 

I claim:
 1. A method of finishing a drywall, comprising the steps of: mixing a predetermined amount of a drywall joint compound with a synthetic fiber and water and applying said mixture as a coat to ajoint between adjacent sheets of sheetrock.
 2. The method of claim 1, further comprising a step of adding a predetermined amount of a liquid adhesive to said mixture before applying said mixture to the joint.
 3. The method of claim 1, wherein the synthetic fiber comprises polypropylene.
 4. The method of claim 1, wherein the synthetic fiber comprises segments having a length of about 0.5 to 1.0 inches.
 5. The method of claim 1, wherein said mixing step further comprises a step of soaking the synthetic fiber in water and then vigorously agitating the drywall joint compound with water and the synthetic fiber to form a homogenous mixture.
 6. The method of claim 5, wherein said step of soaking is performed for about 1-3 minutes.
 7. The method of claim 5, wherein said step of agitating is performed for about 2-5 minutes.
 8. The method of claim 1, wherein the step of mixing comprises mixing about 50 pounds of drywall joint compound with between about 2 ounces to about 8 ounces of water and with between about 4 ounces to about 6 ounces of the synthetic fiber.
 9. The method of claim 2, wherein the step of mixing comprises mixing about 50 pounds of drywall joint compound with between about 2 ounces to about 8 ounces of water, with between about 4 ounces to about 6 ounces of the synthetic fiber, and with between about 3 ounces to about 5 ounces of a liquid vinyl wallpaper adhesive.
 10. The method of claim 1, further comprising a step of allowing said coat to dry for a period of between 20 hours and about 24 hours.
 11. The method of claim 2, wherein said mixture comprises between about 97.68 percent by weight to about 98.8 percent by weight of drywall joint compound, between about 0.247 percent by weight to about 0.97 percent by weight of water, and between about 0.37 percent by weight to about 0.61 percent by weight of the liquid adhesive.
 12. A method of filling a seam of a drywall comprised of abutting panels, the method comprising the steps of: mixing a predetermined amount of a drywall joint compound with a synthetic fiber, liquid adhesive and water and applying said mixture as a coat to the seam between the abutting panels.
 13. The method of claim 12, wherein said step of mixing comprises mixing about 50 pounds of drywall joint compound with between about 2 ounces to about 8 ounces of water, with between about 4 ounces to about 6 ounces of the synthetic fiber, and with between about 3 ounces to about 5 ounces of a liquid vinyl wallpaper adhesive.
 14. The method of claim 12, wherein the synthetic fiber comprises segments having a length of about 0.5 to 1.0 inches.
 15. The method of claim 12, wherein said mixing step further comprises a step of soaking the synthetic fiber in water and then vigorously agitating the drywall joint compound with water and the synthetic fiber to form a homogenous mixture.
 16. The method of claim 12, wherein said mixture comprises between about 97.68 percent by weight to about 98.8 percent by weight of drywall joint compound, between about 0.247 percent by weight to about 0.97 percent by weight of water, and between about 0.37 percent by weight to about 0.61 percent by weight of the liquid adhesive.
 17. A composition, which forms a setting type homogenous drywall joint compound, comprising from about 97.68 to about 98.8 percent by weight of all-purpose joint compound, a synthetic fiber comprising polypropylene soaked in water and mixed with the all-purpose drywall joint compound to form a homogenous drywall joint compound.
 18. The composition of claim 17, in which the synthetic fiber is present in amounts ranging from about 0.484 to about 0.73% by weight of the composition.
 19. The composition of claim 17, in which soaking water is present in a sufficient amount to facilitate mixing.
 20. The composition of claim 19, in which water is present in amounts ranging from about 0.247 to about 0.97% by weight of the composition.
 21. The composition of claim 17, further comprising a liquid adhesive.
 22. The composition of claim 21, in which the liquid adhesive is a liquid wallpaper adhesive present in amounts ranging from about 0.37 to about 0.61% by weight of the composition.
 23. The composition of claim 17, wherein said synthetic fiber comprises polypropylene in segments having length from about 0.5 to 1 inches. 